Method and apparatus for adding loose inserts to magazines

ABSTRACT

Magazine signatures are successively gathered on a saddle to form a series of magazines which are successively stitched at a binding station located at the end of the saddle. A loose insert is added to each magazine by feeding the insert upwardly between depending signature leaves which are separated while the signatures are advanced along the saddle. A spot of glue may be applied to the loose insert being fed into each magazine.

United States Patent Bunting et al.

[54] METHOD AND APPARATUS FOR ADDING LOOSE INSERTS TO MAGAZINES [72] Inventors: Charles W. Bunting; William R. Fortman, both of Dayton; Albert II. Ash, South Vienna, all of Ohio [73] Assignee: McCall Corporation, Dayton, Ohio [22] Filed: July 10, 1970 [21] Appl. No.: 53,807

Related U.S. Application Data [63] Continuation-impart of Ser. No. 766,387, Oct. 10,

I968, abandoned.

[52] U.S. Cl ..270/55, 270/53 [51] Int. Cl ..B65h 5/32 [58] Field of Search ..270/53-55, 57

' [56] References Cited UNITED STATES PATENTS 2,268,600 1/1942 Kleineberg ..270/55 X [451 Apr. 25, 1972 3,169,762 2/1965 Parks ..270/55 3,450,400 6/1969 Guggisberg ..270/55 FOREIGN PATENTS OR APPLICATIONS 396,816 8/1933 Great Britain ..270/54 Primary ExaminerRobert W. Michell Assistant Examiner-L. R. Oremland Attorney-Amster & Rothstein 57 ABSTRACT Magazine signatures are successively gathered on a saddle to form a series of magazines which are successively stitched at a binding station located at the end of the saddle. A loose insert is added to each magazine by feeding the insert upwardly between depending signature leaves which are separated while the signatures are advanced along the saddle. A spot of glue may be applied to the loose insert being fed into each magazine.

22 Claims, 5 Drawing Figures Pmfmgqmzsmz 2,658,318

sum 10F 2 CHARLES w. BUNTING WILLIAM FORTMAN "5 m ALBERT H ASH A I O/{N PATENTEDAPRZS 1972 3,658,318

- sum 2 CF 2 Z W/K/ I CHARLES w. Bumm I WILLIAM R. FORTMAN HY ALBERT H. AH

METHOD AND APPARATUS FOR ADDING LOOSE INSERTS TO MAGAZINES The present application is a continuation-in-part of patent application Ser. No. 766,387, now abandoned, filed Oct. 10, 1968, and assigned to the assignee of the present invention.

The present invention relates to an improved method and apparatus for injecting loose insert material between signature leaves of a magazine.

It is frequently desirable to insert a loose return card or envelope into a magazine for the reader or subscriber to fill out and return to the publisher, as for example, to renew a subscription or to originate a new subscription. In a side stitched or perfect bound magazine where the signatures are arranged in stacked relation, the loose card or envelope is commonly inserted while each magazine is being conveyed by a horizontally extending conveyor and is disposed in a horizontal position. Each magazine is in closed condition, that is, all of its leaves are adjacent one another, but is yet unbound. As each magazine is being conveyed to a binding or trimming station, a plow raises a portion of the signature leaves, and the insert is ejected laterally between a pair of signature leaves.

In a saddle-stitched magazine, that is, a magazine formed by collecting a series of overlapping signatures on a horizontally extending saddle with the signature leaves depending on each side of the saddle, a loose card or envelope is commonly inserted into each magazine after it is bound by first stacking the bound magazines in a hopper after they are trimmed and then successively feeding the magazines from the bottom of the hopper on a horizontally extending conveyor.

A portion of the signature leaves are raised and the insert ejected into each magazine in the same manner as the insert is added to a side stitched or perfect bound magazine. Therefore, to add a loose insert to a saddle-stitched magazine, it is necessary to have an auxiliary machine for collecting the bound magazines in a hopper and for feeding the magazines successively from the bottom of the hopper.

Broadly, an object of the present invention is to provide an improved method and apparatus for including an insert between signature leaves of a magazine. More specifically, an object of the present invention is to provide a method and apparatus for injecting a loose insert between signature leaves of a saddle-stitched magazine while the magazine is being formed.

A further object is to provide an improved method and apparatus for including an insert between signature leaves of a magazine that does not require the additional handling of the assembled magazine as in the above described prior art machines.

Another object of the present invention is to provide a method for injecting loose insert material between signature leaves of a magazine while the overlapping signature leaves of said magazine are supported by the saddle of a saddle type gathering and binding machine.

In accordance with the method aspect of the present invention there is provided a method of producing a magazine having a loose insert therein comprising the steps of gathering a plurality of signature leaves in overlapping relation .on a saddle with the leaves depending downwardly on each side of the saddle, spreading a portion of the depending leaves to form an insert-receiving separation, and feeding an insert in each said separation.

In accordance with the apparatus aspect of the present invention, there is provided an apparatus for producing a magazine including a high speed insert ejector or feeder which is adapted to be positioned adjacent a saddle type gathering and binding machine and preferably at the stitching station where each magazine dwells a fraction of a second for receiving stitches through the overlapping signature leaves supported by the saddle. The apparatus may incorporate a high speed insert ejector including means for applying a spot of glue onto the insert being ejected into the magazine.

Further objects, features and advantages of the present invention will be more fully appreciated by reference to the following illustrative embodiments of the present invention, when taken in conjunction with the accompanying drawings wherein:

FIG. 1 is a fragmentary elevational view of a part of a saddle type gathering and binding machine incorporating the present invention; E

FIG. 2 is a partially schematic elevational section taken along the line 2-2l of FIG. 1;

FIG. 3 is a fragmentary perspective view of the signature gathering portion of the apparatus shown in FIG. 1 and showing a first embodiment of the plow;

FIG. 4 is a fragmentary perspective view of the signature gathering portion of the apparatus similar to that shown in FIG. 3, but illustrating a second embodiment of the plow; and

FIG. 5 is an elevational section similar to that shown in FIG. 2, illustrating a second embodiment of the present invention.

Referring to the drawings, FIG. 1 shows a saddle-stitch, magazine-making machine of a well known type. In general this machine includes a signature gathering unit having a base 12 which supports an elongated horizontally extending saddle 15 which has an inverted V-shaped cross-sectional configuration. An endless chain 16 is directed around a series of sprockets 17 mounted on the base 12 and has an upper run which extends along the top of the saddle 15. A series of outwardly projecting fingers 18 are spaced at intervals along the chain 16 and serve to collect a series of magazine signatures S in overlapping relation as the chain 16 advances past a plurality of signature loading or feeding stations 20. Thus the signatures S are successively gathered on the saddle 15 to form a series of magazines M which are successively advanced to a stitching unit 25.

The stitching unit includes a pair of stitching heads 26 each having a foot 28 which is pressed downwardly against each magazine M while it is supported by a saddle extension 30 which extends horizontally through the stitching unit. After each magazine M is discharged from the continuously running chain 16, it is picked up by an advancing mechanism (not shown) which advances the magazine M along the saddle extension 30 through the stitching unit 25. While each magazine M dwells for a fraction of a second at a binding station 32, the stitching heads 26 move downwardly to clamp the magazine firmly on the saddle extension 30 while a pair of wire staples are inserted and clamped within the central portion of the magazine. After each magazine M is bound, it is directed through a trimmer (not shown) where the magazine is trimmed to size.

In accordance with the present invention, an insert feeding unit is positioned adjacent one side of the stitching unit 25 and includes a base housing 36 which supports a pair of parallel spaced vertical side plates 38. A hopper 40 is supported by a cross bar 4! connecting the side plates 38 and includes a plurality of downwardly sloping fingers 42 which are laterally adjustable on the bar 41. A stack of inserts in the form of cards C is supported by the hopper 40 so that the bottom card C rests against a bottom plate 44 having a curved nose portion 46.

A pair of parallel spaced feed disks 48 are mounted on a cross shaft 49 which is rotatably supported by the side plates 38 and is driven by a variable speed drive 50 located within the housing 36 and driven from the main drive shaft (not shown) of the saddle-stitch, magazine-making machine. Each disk 48 has a recess 52 which defines a forwardly projecting finger 53. A pair of suction tubes 55 are supported adjacent the disks 48 by a block 56 mounted on a cross shaft 58 supported by the side plates 38. A nozzle 60 is mounted on one end of each suction tube 55 and the opposite end is connected by a flexible hose to a suitable suction supply 61 through a solenoid actuated valve 62. An arm 65 is rigidly secured to the cross shaft 58 and is connected by a link 66 to one end of a lever 68 pivotally supported by an axle bolt 69 secured to one of the side plates 38. A roller 71 is mounted on the other end of the lever 68 and engages the outer surface of a cam plate 72 eccentrically mounted on the shaft 49.

A pair of laterally spaced endless belts 75 extend around a roller 76 mounted on a cross shaft 77 positioned adjacent the nose portion 46 of the hopper bottom plate 44. The belts 75 also extend around corresponding rollers 78 mounted on a cross shaft 79 connected to the variable speed drive 50 and around corresponding tension rollers 81 mounted on a cross shaft 82 supported by parallel spaced arms 83 pivotally mounted on a stationary cross rod 84. A set of tension springs 85 connect the arms 83 to the housing 36 for maintaining a predetermined tension within each belt 75 as it is directed around a peripheral portion of the corresponding disk 48 between the rollers 76 and 78.

A pair of endless lower belts 90 are directed around corresponding rollers 92 mounted on a cross shaft 93 which is connected to a drive 94. Each lower belt 90 is also directed around a roller 95 supported by an arm 96 adjustably secured by a screw 97 to a support member 98 adjustably mounted on a cross rod 99 connecting the side plates 38.

A pair of upper belts 100 are directed around another set of drive rollers 92 mounted on another cross shaft 93 connected to the drive 94. Each upper belt 100 is also directed around a guide roller 102 and an end roller 104 supported by an arm S adjustably secured by a screw 106 to a support member 107 mounted on a cross rod 108. The belts 90 and 100 are driven by the drive 94 at a speed considerably higher than the speed of the belts 75. The belts 90 and 100 are in juxtaposition and cooperate to define a linear run 110 which is inclined upwardly from the guide roller 102 to the end rollers 95 and 104.

A safety device such as a clutch may be provided on the output shaft of variable speed drive 50 for disconnecting the drive source should a jam-up occur within the mechanical parts of the above-described insert feeding unit 35.

A plow in the form of an elongated wire 115 (see FIGS. 1, 2, 3 and 5) extends from the feeding unit 35 to a support 116 which is secured to the base 12 and positioned between a preselected pair of adjacent signature feed stations 20. Thus, the leaves L of the signatures S gathered on the saddle at the stations following the support 116 are held away from the leaves previously gathered on the saddle 15 at the stations preceding the support 116. As the signatures move on the saddle 15 towards the stitching unit 25, the wire 115 maintains a generally inverted V-shaped, insert-receiving separation 120 between the preselected pair of adjacent signature leaves L of each magazine M.

With reference to FIG. 4, the inverted V-shaped separation 120 between adjacent signature leaves of each magazine M may be formed by a plow 130 positioned immediately ahead of the stitching unit and having a generally flat configuration with a tapered tip 131 extending in the path of movement of the magazines. Plow 130 is disposed in a horizontal plane and is fastened to a support bracket 132 which is secured to the base 12. While each of the magazines supported by the saddle 15 is approaching the stitching unit 25, the common leading edges of the gathered leaves thereof strike the plow 130 and the plow 130 thereupon enters and spreads a portion of the depending leaves L on one side of the saddle 15 to form an inverted V-shaped, insert-receiving separation 120 between adjacent leaves L. The insert-receiving separation 120' for each magazine is thereby located at random. The insert C is then ejected upwardly into the separation at the same time that the overlapping signatures S supported by saddle 15 are being clamped and stitched. The use of plow 130 is particularly suited to those situations where it is permissible to have random location of the loose insert within each magazine.

When each magazine M arrives at the binding station 32, it dwells for a fraction of a second at which time the stitching feet 28 press the central portion of the magazine against the upper surface of the saddle extension 30. The solenoid valve 62 is opened to operatively connect the suction tubes 55 to the suction supply 61 thereby causing the end portion of the bottom card C within the stack supported by the hopper to adhere to the nozzles 60 of the suction tubes 55. The rotation of cam plate 72 via lever 68 and link 66 will rock the suction tubes 55 toward shaft 49 so that, with the solenoid valve 62 open, the end portion of the bottom card C will be drawn into the recesses 52 of the rotating feed disks 48. After this action, the valve 62 is closed, removing the suction, and the forwardly projecting finger 53 of each rotating feed disk 48 bends said end portion around the nose portion 46 of the bottom plate 44 and sandwiches the end portion between the feed disks 48 and the belts 75.

The bottom card is then drawn between moving belts 75 and the feed disks 48 out from the hopper 40 and is transported between said belt and disks. The card is discharged from between the disks 48 and belts 75 into the adjacent runs of the belts and which rapidly advance the card and eject it upwardly into the space so that the leading edge of the card is wedged between the adjacent signature leaves L defining the space 120. To perform the card inserting operation simultaneously with the stitching operation, the actuation of the solenoid valve 62 and the speed of the drive unit 50 are controlled in timed relation with the drive for the endless chain 16 and the drive for the step-by-step advancement of each magazine through the stitching unit 25.

In a second embodiment of the present invention, illustrated in FIG. 5, an adhesive system is provided for applying a spot of glue onto the loose inserts being ejected into the magazines. The glue adhesive is contained within glue pot and is picked up from the pot by adhesive roller 142, mounted on rotating shaft 144 which is connected to drive 145. A doctor blade 148 is positioned over glue pot 140 and has a leading edge 150 in close proximity with adhesive roller 142 to remove excess glue. Applicator wheel 152 having a tongue 154 is mounted on shaft 79 for rotation between the belts 75.

In operation, glue is maintained on adhesive roller 142 by its rotation through glue pot 140. The leading edge 150 of blade 148 controls the thickness of the film of glue adhesive maintained on said adhesive roller. As applicator wheel 152 rotates about shaft 79, tongue portion 154 wipes glue from adhesive roller 142 and transports the glue so obtained to the loose insert passing between feeder wheels 48 and belts 75. Thus, a spot of glue is placed on a loose insert traveling through the card feeding unit 35 as herein described above.

The foregoing description is intended to be merely illustrative of preferred embodiments of the present invention. .A latitude of modification, change and substitution is intended wherein some features of the invention will be employed without a corresponding use of other features so described hereinabove. Accordingly, various modes of carrying out the invention are contemplated as being within the scope of the following claims.

What is claimed is:

1. In apparatus for successively binding a succession of magazines each formed by collecting a series of signatures in overlapping relation, and including a saddle for supporting the overlapping signatures in straddling relation with the leaves of the signatures on opposite sides of the saddle, a binding station, means for advancing the signatures on said saddle towards said binding station, and means positioned at said binding station for securing together the signatures forming each magazine while the signatures are supported by said saddle; a mechanism for adding a loose insert to each magazine comprising means for spreading a portion of the depending signature leaves of each magazine on said saddle to form an insert-receiving space between two adjacent leaves and means for feeding an insert into said insert-receiving space within each magazine while supported by said saddle.

2. Apparatus according to claim 1 wherein said advancing means momentarily stops each magazine at said binding station, and said feeding means is positioned to eject an insert into said insert-receiving space within each said magazine while the magazine is stopped at said binding station.

3. Apparatus according to claim 1 including means associated with said saddle for holding the signatures of each magazine against said saddle while an insert is fed into said insert-receiving space within the magazine.

4. Apparatus according to claim 3 wherein said means for holding the signatures against the saddle comprises a movable clamping head forming a part of said securing means.

5. Apparatus according to claim 1 wherein said spreading means comprises a plow positioned adjacent said saddle and extending in the path of movement of the magazines on said saddle for producing said insert-receiving space within each magazine while the magazines are advanced on said saddle.

6. Apparatus according to claim 1 including means for spreading a predetermined portion of said depending signature leaves to provide for adding a loose insert between two preselected adjacent leaves.

7. Apparatus according to claim 6 further including a plurality of signature loading stations, and wherein said spreading means includes an elongated member extending from said insert-feeding means to a position along said saddle between a preselected pair of said loadingstations so that the leaves of the signatures gathered on said saddle after said position are held away from the overlapping signatures gathered before said position.

8. Apparatus according to claim 1 including means for applying adhesive onto the insert being fed into said insertreceiving space within the magazine.

9. Apparatus according to claim 8 wherein said means for applying adhesive includes an applicator wheel having a tongue and mounted for rotation about an axis, whereby said tongue is brought into contact with said insert.

10. Apparatus according to claim 1 wherein said means for spreading a portion of the depending leaves includes a plow having a tip extending in the path of advancement of the magazines for randomly locating and forming an insert-receiving separation between adjacent depending leaves of said magazine.

11. The combination with apparatus for successively gathering and binding a series of signatures in overlapping relation to form a succession of magazines, and including a saddle for supporting the overlapping signatures in straddling relation with the leaves of the signatures hanging downwardly on each side of the saddle, a binding station, means for successively advancing the signatures on said saddle towards said binding station, means positioned at said binding station for securing together the signatures forming each magazine while the signatures are supported by said saddle; a mechanism for adding a loose insert into each magazine comprising means providing a supply of inserts and means for feeding an insert into each said magazine while the magazine is supported by said saddle.

12. The combination according to claim 11 wherein said means providing a supply of inserts includes a hopper for receiving a supply of said inserts.

13. The combination according to claim 12 further including means for spreading a portion of the depending signature leaves of each magazine on said saddle to form an insertreceiving space between two adjacent leaves.

14. The combination according to claim 13 wherein said means for feeding inserts includes at least one rotary feed member positioned adjacent said hopper means and having a curved outer surface, means associated with said feed member for successively transferring the inserts from said hopper means to said outer surface of said feed member and means positioned adjacent said feed member for successively receiving the inserts from said surface of said feed member and directing each insert into said insert-receiving space within each magazine.

15. The combination according to claim 14 wherein said transferring means comprises a recess on said feed member, and at least one movable suction member adapted to pull a portion of each insert into said recess.

16. The combination according to claim 14 wherein said receiving and directing means comprises a set of endless belts in juxtaposition for receiving each insert therebetween, and means for positioning said set of endless belts for accurately directing each insert into said space within each ma azine.

17. A method of producing a magazine having a oose insert therein comprising the steps of progressively gathering a plurality of magazine signatures in overlapping relation on a saddle so that the signature leaves depend downwardly on each side of the saddle, spreading a portion of the depending leaves on one side of the saddle to form an insert-receiving separation between adjacent leaves, and feeding an insert into each said separation while the overlapping signatures are supported by said saddle.

18. A method according to claim 17 including the step of applying adhesive onto the insert being fed into said insertreceiving separation.

19. A method according to claim 17 including the steps of momentarily stopping each magazine on said saddle to perform a binding operation, and holding the signature leaves against the saddle while feeding an insert into said separation.

20. A method according to claim 17 including the step of spreading a predetermined portion of the depending leaves on one side of the saddle to form an insert-receiving separation between predetermined leaves of each magazine.

21. A method according to claim 17 wherein the step of spreading a portion of the depending leaves takes place while the magazine signatures are being progressively gathered on said saddle.

22. A method according to claim 17 wherein the step of spreading a portion of the depending leaves takes place after the magazine signatures have been progressively gathered on said saddle. 

1. In apparatus for successively binding a succession of magazines each formed by collecting a series of signatures in overlapping relation, and including a saddle for supporting the overlapping signatures in straddling relation with the leaves of the signatures on opposite sides of the saddle, a binding station, means for advancing the signatures on said saddle towards said binding station, and means positioned at said binding station for securing together the signatures forming each magazine while the signatures are supported by said saddle; a mechanism for adding a loose insert to each magazine comprising means for spreading a portion of the depending signature leaves of each magazine on said saddle to form an insert-receiving space between two adjacent leaves and means for feeding an insert into said insert-receiving space within each magazine while supported by said saddle.
 2. Apparatus according to claim 1 wherein said advancing means momentarily stops each magazine at said binding station, and said feeding means is positioned to eject an insert into said insert-receiving space within each said magazine while the magazine is stopped at said binding station.
 3. Apparatus according to claim 1 including means associated with said saddle for holding the signatures of each magazine against said saddle while an insert is fed into said insert-receiving space within the magazine.
 4. Apparatus according to claim 3 wherein said means for holding the signatures against the saddle comprises a movable clamping head forming a part of said securing means.
 5. Apparatus according to claim 1 wherein said spreading means comprises a plow positioned adjacent said saddle and extending in the path of movement of the magazines on said saddle for producing said insert-receiving space within each magazine while the magazines are advanced on said saddle.
 6. Apparatus according to claim 1 including means for spreading a predetermined portion of said depending signature leaves to provide for adding a loose insert between two preselected adjacent leaves.
 7. Apparatus according to claim 6 further including a plurality of signature loading stations, and wherein said spreading means includes an elongated member extending from said insert-feeding means to a position along said saddle between a preselected pair of said loading stations so that the leaves of the signatures gathered on said saddle after said position are held away from the overlapping signatures gathered before said position.
 8. Apparatus according to claim 1 including means for applying adhesive onto the insert being fed into said insert-receiving space within the magazine.
 9. Apparatus according to claim 8 wherein said means for applying adhesive includes an applicator wheel having a tongue and mounted for rotation about an axis, whereby said tongue is brought into contact with said insert.
 10. Apparatus according to claim 1 wherein said means for spreading a portion of the depending leaves includes a plow having a tip extending in the path of advancement of the magazines for randomly locating and forming an insert-receiving separation between adjacent depending leaves of said magazine.
 11. The combination with apparatus for successively gathering and binding a series of signatures in overlapping relation to form a succession of magazines, and including a saddle for supporting the overlapping signatures in straddling relation with the leaves of the signatures hanging downwardly on each side of the saddle, a binding station, means for successively advancing the signatures on said saddle towards said binding station, means positioned at said binding station for securing together the signatures forming each magazine while the signatures are supported by said saddle; a mechanism for adding a loose insert into each magazine comprising means providing a supply of inserts and means for feeding an insert into each said magazine while the magazine is supported by said saddle.
 12. The combination according to claim 11 wherein said means providing a supply of inserts includes a hopper for receiving a supply of said inserts.
 13. The combination according to claim 12 further including means for spreading a portion of the depending signature leaves of each magazine on said saddle to form an insert-receiving space between two adjacent leaves.
 14. The combination according to claim 13 wherein said means for feeding inserts includes at least one rotary feed member positioned adjacent said hopper means and having a curved outer surface, means associated with said feed member for successively transferring the inserts from said hopper means to said outer surface of said feed member and means positioned adjacent said feed member for successively receiving the inserts from said surface of said feed member and directing each insert into said insert-receiving space within each magazine.
 15. The combination according to claim 14 wherein said transferring means comprises a recess on said feed member, and at least one movable suction member adapted to pull a portion of each insert into said recess.
 16. The combination according to claim 14 wherein said receiving and directing means comprises a set of endless belts in juxtaposition for receiving each insert therebetween, and means for positioning said set of endless belts for accurately directing each insert into said space within each magazine.
 17. A method of producing a magazine having a loose insert therein comprising the steps of progressively gathering a plurality of magazine signatures in overlapping relation on a saddle so that the signature leaves depend downwardly on each side of the saddle, spreading a portion of the depending leaves on one side of the saddle to form an insert-receiving separation between adjacent leaves, and feeding an insert into each said separation while the overlapping signatures are supported by said saddle.
 18. A method according to claim 17 including the step of applying adhesive onto the insert being fed into said insert-receiving separation.
 19. A method according to claim 17 including the steps of momentarily stopping each magazine on said saddle to perform a binding operation, and holding the signature leaves against the saddle while feeding an insert into said separation.
 20. A method according to claim 17 including the step of spreading a predetermined portion of the depending leaves on one side of the saddle to form an insert-receiving separation between predetermined leaves of each magazine.
 21. A method according to claim 17 wherein the step of spreading a portion of the depending leaves takes place while the magazine signatures are being progressively gathered on said saddle.
 22. A method according to claim 17 wherein the step of spreading a portion of the depending leaves takes place after the magazine signatures have been progressively gathered on said saddle. 